Mattress construction

ABSTRACT

A mattress formed of soft, low density resilient foam material which conforms to the body weight and contour. The upper portion of the mattress is divided into a plurality of separate portions which are individually compressible in respect to body weight. A plurality of partially compressed coil springs are mounted within cylindrical slits formed in the lower part of the mattress beneath each separate portion. The springs provide added strength for body support and assure prompt return of the upper part of the resilient material to its normal shape when weight is removed from it.

United States Patent 1 1 Frey [541 MATTRESS CONSTRUCTION [76] Inventor: Louis Elliott Frey, 1271 East Sixth Street, Los Angeles, Calif. 90021 [22] Filed: Aug. 6, 1971 21 Appl. No.: 169,652

[52] U.S. C1 ..5/345, 5/91 [51] Int. Cl ..A47c 23/00 [58] Field of Search ..5/24 6, 248, 256, 5/345, 351, 353, 91, 357

[56] References Cited UNITED STATES PATENTS 3,191,197 6/1965 Frey ..5/353 X 3,623,171 11/1971 Arkin....=...

3,401,411 9/1968 Morrison ..5/353 11 3,732,586 51 May 15, 1973 Primary Examiner-James T. McCall Assistant ExaminerAndrew M. Calvert A ttorney Robert C. Comstock 57 ABSTRACT A mattress formed of soft, low density resilient foam material which conforms to the body weight and contour. The upper portion of the mattress is divided into a plurality of separate portions which are individually compressible in respect to body weight. A plurality of partially compressed coil springs are mounted within cylindrical slits formed in the lower part of the mattress beneath each separate portion. The springs provide added strength for body support and assure prompt return of the upper part of the resilient material to its normal shape when weight is removed from it.

9 Claims, 3 Drawing Figures BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to a new and improved construction for mattresses.

2. Description of the Prior Art The present invention relates to an improvement over the mattress construction shown and described in my prior U.S. Pat. No. 3,191,197. The mattress shown in that patent was divided into a plurality of separate block-like sections, each of which was capable of limited independent vertical movement.

The most feasible material for use in constructing such a mattress is resilient foam. It has been found, however, that resilient foam which has sufficient density to support the weight of a person is hard to the touch and does not provide the type and degree of softness which is desirable for a mattress. Such material also has a slow recovery due to its heavy density and it accordingly tends to take and hold a set. This is an undesirable and unsatisfactory characteristic in a mat tress.

SUMMARY OF THE INVENTION The invention comprises a mattress which is formed of relatively low density resilient foam material which will substantially conform to the contour of every part of the body and which provides the degree of softness which is desirable in a mattress. The upper portion of the mattress is divided into a plurality of separate block-like sections of the type shown in my prior U.S. Pat. No. 3,191,197. Mounted beneath each of these block-like sections is a compressed spring which provides the strength necessary to support the body and which acts to prevent the foam material from taking a set, as it is inherently inclined to do.

The spring is inserted and held in a compressed condition within the lower portion of the mattress beneath each block, to provide the necessary body support and strength when the upper portion of the block is depressed by the weight of a portion of the body. This construction provides the body-responding comfort of a soft light form with strength and support equal to that of more dense and rigid foam material.

The spring preferably comprises a substantially frusto-conical coil spring which is mounted in a cylindrical slit cut or otherwise formed beneath the center of each block-like section of the mattress. A frusto-conical spring provides the desired amount of progressively increased support as it is depressed in use.

It is accordingly among the objects of my invention to provide a mattress construction having all of the advantages and benefits of the structure set forth above and described in detail hereinafter in this specification.

Another object of the invention is to provide a mattress having a plurality of block-like sections which are capable of independent vertical movement and which also have the desired softness and comfort combined with the strength for proper body support.

A further object of the invention is to provide a mattress of the type described which will not take a set and in which the upper surface will return to a flat horizontal position as soon as the weight of the body is removed from it.

' Still another object of the invention is to provide such a mattress which is simple and economical to manufacture, so that it can be manufactured and sold at a reasonable price. My invention also comprises such other objects, advantages and capabilities as will later more fully appear and which are inherently possessed by my invention.

While I have shown in the accompanying drawings preferred embodiments of my invention, it should be understood that the same are susceptible of modification and change without departing from the spirit of my invention.

DESCRIPTION OF THE DRAWINGS FIG, 1 is an isometric view of a mattress constructed in accordance with my invention, with the springs shown in phantom lines, the upper portion of the left hand side of the mattress being divided into block-like sections and the right hand side being divided into elongated sections;

FIG. 2 is a partial sectional view of the same taken along line 2-2 of FIG. 1;

FIG. 3 is a bottom plan view of one of the block-like sections shown on the left hand side of FIG. 1, showing the slit before the spring is inserted.

DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment which has been selected to illustrate my invention comprises a mattress 10, which is preferably formed of suitable resilient foam material. The mattress 10 includes an integral border 11, which extends around all four sides of the mattress and an integral lower portion 12, which extends across the bottom of the entire area defined by the border 11.

The central upper portion 23 of the mattress. which is disposed above the lower portion 12 is provided as shown on the left side of FIG. 1 with a plurality of intersecting vertical and horizontal slits 13, which preferably extend downwardly approximately half the distance between the top of the mattress and the top of the lower portion 12. The slits l3 divide the central portion 23 into a plurality of adjacent block-like sections 14, each of which is individually compressible in respect to a weight placed thereon in use.

The block-like sections 14 may extend across the entire area defined by the border 11. They may also cover only the major portion of this area, as shown in FIG. 1 of the drawings, with a pair of larger rectangular blocks 15 being disposed adjacent to the head and foot of the mattress between the sections 14 and the border 11.

The exposed surfaces of the mattress may be covered with suitable cloth, flocking or other suitable covering means as desired. Various methods of forming and covering such a mattress are shown and described in my prior U.S. Pat. No. 3,191, 197, the contents of which are incorporated herein by reference. The present invention is directed toward the use of a spring member to reinforce the independently movable block-like sections of a mattress such as that shown in U.S. Pat. No. 3,191,197.

Beneath the center of each of the sections 14 a circular slit 16 is provided by cutting, molding or other suitable means. The slit 16 extends inwardly to a point substantially aligned with the lower or inner ends of the slits 13 which define the sections 14. The area within each of the slits 16 comprises a cylindrical core 17 of resilient foam material.

A frusto-conical coil spring 18 is inserted into each of the slits 16 with its larger diameter end disposed toward the inner or upper end of the slit 16. The length of the slit 16 is preferably approximately half the normal expanded length of the spring 18. The spring 18 when it is disposed entirely within the slit 16 is accordingly compressed to approximately half its normal expanded length.

The bottom of the slit 16 is preferably covered by backing material such as treated buckram or other suitahle material which is adhered or otherwise secured to the bottom of the sections 14. The backing material 20 may comprise a single piece of material which extends across the bottom of the entire spring area 23.

The backing material 20 acts to prevent the springs 18 from coming out of the slits 16. The previously mentioned engagement between the coils of the springs 18 and the cores 17 prevents the springs 18 from exerting undue pressure against the backing material 20.

The same coil spring structure described above may also be used with a mattress having a plurality of elongated longitudinal sections 19 instead of block-like sections. Such a structure is shown in FIG. 1 of the drawings on the right hand side. In such a structure, a plurality of coil springs 18 are mounted in slits spaced along the lower portion of each of the longitudinal sections, with the springs and foam material inter-acting in the same manner described above.

Coil springs 18 may also be used in part or all of the border 11 and/or the blocks 15.

In use, this structure provides all of the advantages and benefits contemplated by my prior US. Pat. No. 3,191,197 with regard to the independent movement of the mattress sections and their individual response to body weight and movement. It also provides a definite improvement in that a relatively soft foam material may be used to provide the desired body comfort and easy resilient response while the coil springs disposed within the mattress sections provide the necessary support and return the foam material to its uncompressed state.

It will be noted that the mattress has a relatively thick upper portion which is formed entirely of substantially low density resilient foam material which is divided into separate sections and which is capable of adjusting to the natural contours of the body. Beneath this relatively thick upper portion is a lower portion in which the foam material is reinforced by a compressed coil spring which serves the dual purpose of providing added strength to support the body without requiring the use of undesirable and unsatisfactory high density foam and of urging the upper portion of the mattress back to its normal condition after the weight of the body has been removed from it.

It will also be noted that the upper ends of the springs are disposed so deeply within the foam material that they do not cause discomfort to the mattress user, nor do they disturb the smooth upper surface of the mattress.

The coil springs are preferably completely enclosed within the foam material, so that they are securely held in place and the mattress user is unaware of their existence or action.

I claim:

1. A mattress comprising a resilient member constructed of substantially soft, low density foam material, the upper part of said mattress being divided into a plurality of relatively thick separate portions which are individually compressible in respect to the weight placed thereon in use, the lower part of each of said mattress portions having at least one vertically directed cylindrical slit, and a plurality of coil springs mounted within said slits, said coil springs being held within said mattress in partially compressed condition.

2. The structure described in claim 1, said coil springs being frusto-conical, with their larger ends disposed at the upper ends of said slits.

3. The structure described in claim 2, said mattress having a plurality of block-like portions of substantially square shape, one of said coil springs being mounted beneath the center of each of said portions.

4. The structure described in claim 2, said mattress having a plurality of longitudinally extending elongated portions, and a plurality of spaced coil springs mounted beneath each of said elongated portions.

5. The structure described in claim 2, each of said coil springs being completely surrounded by a substantial thickness of foam material.

6. The structure described in claim 3, each of said coil springs being completely surrounded by a substantial thickness of foam material.

7. The structure described in claim 1, the area within each of said slits comprising a cylindrical resilient core, the coils of said springs engaging said cores to hold said springs in partially compressed condition.

8. The structure described in claim 2, the area within each of said slits comprising a cylindrical resilient core, the coils of said springs engaging said cores to hold said springs in partially compressed condition.

9. The structure described in claim 8, and a layer of backing material extending across the bottom of said mattress to hold said springs within said slits. 

1. A mattress comprising a resilient member constructed of substantially soft, low density foam material, the upper part of said mattress being divided into a plurality of relatively thick separate portions which are individually compressible in respect to the weight placed thereon in use, the lower part of each of said mattress portions having at least one vertically directed cylindrical slit, and a plurality of coil springs mounted within said slits, said coil springs being held within said mattress in partially compressed condition.
 2. The structure described in claim 1, said coil springs being frusto-conical, with their larger ends disposed at the upper ends of said slits.
 3. The structure described in claim 2, said mattress having a plurality of block-like portions of substantially square shape, one of said coil springs being mounted beneath the center of each of said portions.
 4. The structure described in claim 2, said mattress having a plurality of longitudinally extending elongated portions, and a plurality of spaced coil springs mounted beneath each of said elongated portions.
 5. The structure described in claim 2, each of said coil springs being completely surrounded by a substantial thickness of foam material.
 6. The structure described in claim 3, each of said coIl springs being completely surrounded by a substantial thickness of foam material.
 7. The structure described in claim 1, the area within each of said slits comprising a cylindrical resilient core, the coils of said springs engaging said cores to hold said springs in partially compressed condition.
 8. The structure described in claim 2, the area within each of said slits comprising a cylindrical resilient core, the coils of said springs engaging said cores to hold said springs in partially compressed condition.
 9. The structure described in claim 8, and a layer of backing material extending across the bottom of said mattress to hold said springs within said slits. 